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By Joerg Hammerschmidt, Marcus Runkel, Steffen Haus

Given the limited number of new plant construction, focus is turning to the optimization of existing metallurgical roasting plants. To meet the goals of high process efficiency with limited capital expenditure, plant owners are looking for new strategies, including digitization and expert support. As a supplier for numerous roasting, gas cleaning and sulfuric acid plants, Outotec has intensified its effort in recent years to develop solutions to accommodate increasing customer need. This article presents a short review on how Outotec is applying advanced control tools for the fluidized bed industry. Focus will be given on how to transfer the existing technology (used in selected Zinc roasting plants for over a year now) to copper roasting. Outotec has developed the Pretium Roaster Optimizer, a system based on heat and mass-balanced simulation models. Direct experience with this technology will be shared and will highlight similarities to the Partial and Sulfate Copper roasting processes. Pretium detects equipment and plant bottlenecks and provides consistency in process development. The Pretium program combines 24/7 advanced online digitalization tools, along with expert personal support when required. INTRODUCTION Fluidized bed reactors have been used for commercial-scale zinc and copper roasting since the 1950s. While the principles of roasting remain unchanged, over time, the technology has advanced to improve process control of roasting plants. In the past, environmental and safety standards were the driving forces for improvement of equipment and plant design. Today, the emphasis is on plant efficiency and optimization. Another change has come in process control philosophy. While plant control and operation have traditionally been the responsibility of owner/operators, they have now shifted to include both integrated digital tools and specific know-how from engineering companies. This can be seen from the earliest design stages through commissioning and into production, as evidenced by zinc roasting plants in Mexico, Brazil and Turkey.

Jan 1, 2019

By Osvaldo A. Bascur

Industrial complexes rely on measurements of flow rates, qualities, and concentrations for monitoring and optimizing their operation. Corporations use the data from the various sensors and measurements to make business decisions, which affect the profitability of the operation. However, gross errors, due to a variety of reasons like faulty sensors, bad instrument calibration, or incorrect process models may corrupt the actionable information supplied to operations, quality managers, and maintenance personnel. The solution is to use the sophisticated new tools to model the process, sift through the available data to locate the gross errors, and use statistical data reconciliation to validate the sensors and instruments. In this way the data are unified to give the most accurate plant information for use by the monitoring and decision making processes. Most mining and metallurgical plants use predictive maintenance policies based on statistical analysis and special techniques, like vibration analysis, and oil and lube analysis for critical equipment. Process control strategies are installed in several metallurgical sites. All of these depend on reliable and accurate data. The data unification methods validate the individual measurements by using the concept of balances and statistical techniques where each instrument is no longer independent of the other measurements in the facility. This paper refers to the data unification and analysis methods required for profitable plant operations. Continuous improvement and monitoring of the measurement system at the plant and analysis of the reconciled data provide the best information for the decision-making process. On-line gross error detection and elimination methods are required to ensure efficient evaluation of process performance and process optimization. An open discussion of the new methods for gross error detection and data unification will be presented.

May 1, 2001

By Jeremy D. Glennon

A number of exciting challenges, opportunities and unanswered questions remain concerning the chemistry, geochemistry, medical, industrial and analytical applications of gold and its compounds.1 Among the challenges presented is the need for extraction methods for gold, at process and indeed analytical scales, that avoid the use of organic solvents or hazardous reagents. Extensive environmental contamination has occurred in the Brazilian Amazon from the mercury-gold amalgamation process. Major problems with the cyanidation process are the relatively slow dissolution kinetics and the health and environmental problems associated with it. With innovation and technical changes, a cleaner way for solubilising and extracting this versatile precious metal can be found. This cleaner future may lie in supercritical fluid science. Interestingly, geochemical studies of gold solubility and speciation in hydrothermal solutions have highlighted the importance of supercritical conditions and sulphur species in the deposition of gold in natural environments. Gold solubility in supercritical brines is far higher than previously supposed while interest in the high content of carbon dioxide in the mineralizing fluids is growing. 2,3 In recent years, also, there has been a tremendous amount of attention paid in analytical chemistry and in industry, to the area of supercritical fluid extraction (SFE) of organic and metallic species. 4 This interest has been fuelled by the introduction of more stringent environmental control and the subsequent need for cleaner solvents and processes to replace established ones. Carbon dioxide is the substance of choice for SFE because of its moderate critical parameters (Tc = 31oC, Pc = 73atm), inertness and availability in pure form. It is an excellent extraction medium for non-polar and moderately polar species, and with careful ligand design, it can be used for analytical and process scale metal extraction from solution and solid phases. In general, the dissolution of a metal in supercritical CO2 (sc-CO2) requires that the charge on the metal ion be neutralised on complexation by the ligand or through a form of ion pairing (analogous to the situation where metal ions are extracted into organic solvents, such as methyl isobutyl ketone or toluene). In this way, then, many chelating agents such as dithiocarbamates and hydroxamic acids have been utilised to extract metal ions such as Cu and Fe into sc- CO2, the process greatly enhanced by the use of fluorinated ligand derivatives. 5-7 In this review paper, we show that supercritical conditions and complexation with sulphur donor atoms, important in the natural deposition of gold, can form the basis of a clean, eco-friendly chemistry for gold extraction. Analytical scale extractions of gold from a variety of matrices can be conveniently used to assess the efficiency of any new proposed ligand.

Oct 1, 2003

By Jian-bin Xie, Lin-fang Shen, Zhi-liang Wang

"In order to research temperature field for construction of connecting passage in Metro using artificial freezing method, the finite difference software FLAC3D is employed to numerically simulate construction process of connecting passage. During construction, the overall distribution of temperature field around connecting passage, the relationship between soil temperature and freezing time, the distribution and variation for the thickness of freezing wall are studied from the perspective of numerical analysis. The results show as follows: after 55 days’ freezing, the soil temperature surrounding connecting passage is about -24 oC ~ -28 oC, and the minimum thickness of freezing wall is about 4.0m, which is larger than the design value 3.1m. So construction conditions have satisfied to the excavation of connecting passage and pumping station. During the excavation of connecting passage, soil temperature has almost no obvious change and the thickness of freezing wall remains constant mainly. After 45 days’ normal thawing, the temperature of freezing wall rises 12 oC approximately. And the soil temperature rises faster at the beginning of the normal thawing stage. In the whole process of construction, the frozen area is about 5m outside the edge of connecting passage, and the cooling area is about 10m outside the edge of connecting passage. INTRODUCTIONThe first recorded application of the artificial freezing method is on a mineshaft project in 1862, and it has been widely used in foundation pit engineering, subway tunnels, mine shaft engineering and so on (Wang Zhiliang, 2010; Zhang Juanxia, 2012; Qiu Fan, 2007; Zhou Xiaomin, 1999). This method has many advantages of enhancing soil strength; decreasing permeability and adopting various unstable soils (silt clay, sand, gravel, etc.). It has been applied successfully in metro engineering construction in Beijing, Shanghai and Nanjing. According to incomplete statistics, the construction of connecting passage using artificial freezing method accounted for 98% in Shanghai metro (Qiu Fan, 2007)."

Jan 1, 2015

By M. Imamura

Sumitomo Metal Mining Co., Ltd. has developed a novel hydrometallurgical process for producing not only copper metal but also iron metal from copper concentrates. Because copper concentrates generally contains the same amount of iron as copper, cost-effective rejection of the iron is a key issue for the development of the process. Conventional hydrometallurgical processes produce a large volume of goethite or hematite for disposal and the residues are not environmentally friendly. In the novel Sumitomo hydrometallurgical process, copper is leached effectively from chalcopyrite concentrates using chlorine gas, followed by purification through solvent extraction and electrowinning for copper and iron recovery. This process has many advantages such as the minimization of the volume of solid waste by the recovery of metallic iron and the production of high purity copper. Iron metal with a purity of more than 98% can be recovered from the purified raffinate. This paper presents the results of the batch and continuous tests of the process flowsheet.

Jan 1, 2006

By Ian S. Leslie

Seismic monitoring systems for mining operations are being utilized more than ever before in the characterization of rock mass response to underground and open pit mining. This paper provides a review of the use of microseismic monitoring for rock mechanics applications at mines throughout the world. Some practical considerations for the installation of these systems are presented along with techniques for optimizing seismic array coverage. Case studies and installation examples are also provided. Recent applications of advanced seismic analysis techniques are discussed including the determination of event mechanisms, mapping of maximum peak particle velocity (PPV) and seismic hazard fields, and the use of source parameter data for large event re-entry protocol.

Jun 1, 2012

By B. Schulz, T. Leißner, R. G. Merker

"Ores enriched in critical rare earth elements (CREE) keep on being of particular interest. The CREE are Nd, Eu, Tb, Dy, including Y. In conjunction with beneficiation tests on Y-mineral bearing flotation tailings of complicated mineralogy, the Mineral Liberation Analyses (MLA) was used to work out processing characteristics fraction-wise in terms of modal mineralogy, mineral recovery, locking and liberation, and particle size.Size fractions from mechanical sieving (“real fractions”) as well as fractions created virtually by using filters on the MLA-data of the unsieved head material (“virtual fractions”) were investigated comparatively thereby. The ""virtual-sizing-approach"" features a much simpler sample preparation procedure and considerably lower cost if a fraction-wise investigation of a head sample is needed. It can be conveniently applied to intimately locked ores needing a fine grinding to a particle size distribution (PSD) range below 25 microns for instance. However, its practical use is sometimes disputed in terms of the reliability of the results. Results are shown for the main Y-bearing mineral xenotime and selected main gangue minerals of a low grade REE-ore.The influence of sample representativeness, sample preparation and particle counting statistics turned out to be of crucial importance. Given that all preconditions for reliable results are met, locking characteristics, modal mineralogy, and even PSD trends can be read from virtual fractions.The authors encourage processing engineers to use the virtual approach. They propose practical measures to improve the reliability of the MLA results, identify and tackle conflicting results, and mitigate evaluation problems that may arise."

Jan 1, 2016

By S. H. Logan

The present discussions throughout the civilized world on the subject of gold for monetary purposes may seem due to general economic conditions during the past year. But for some years previously a small group of authorities had warned the world against the continued disregard of an equitable distribution of existing gold reserves, and had urged the necessity of keeping the supply of new gold equal to the monetary demand, which, according to world production and trade figures, increases on the average about 3 per cent per annum. In 1927, Sir John Aird, the President of The Canadian Bank of Commerce, stated that the United States could spare a billion dollars of the supply it then held, 4 ½ billion dollars. About a year and a half ago the Professor of Banking and Currency in the University of London, Mr. T. E. Gregory, said, "If the world finds it impossible to modify its habits so far as to make an organized effort to economize gold seem less Utopian, it must be prepared to pay for its bad habits, in this and other respects, by a possible loss of material welfare." These clear-cut statements were not heeded, perhaps for one reason because most countries were in the flush of prosperity, and making such great demands upon the mining fraternity for industrial materials as to distract attention, at least to some degree, from gold mining. Now the world knows it faces serious problems, first, of making? fully effective its present monetary reserves, which, although badly distributed, are as a whole ample for the needs of the present, and secondly, of preventing a shortage in the supply of new gold, one that may come within the next few years if the present sources of supply are not enlarged, and if there is no marked change in the technique of gold production.

Jan 1, 1931

By The Staff

This is in direct contradiction to the generally accepted philosophy of tube-mill grinding, which is based upon an enormous amount of experiment carried on in different parts of the world. Personally, I have no faith in the reliability of these conclusions of the authors. (Incidentally, the two circuits compared consist of six mills each of which the change in the hook-up is only in the last three mills-in one case, these three mills are in closed circuit and in the other, open or series circuit. Hence the last three mills are alone responsible for the alleged improvement, which means that the improvement in these three mills amounts to at least 18.8 per cent). The value of these figures depends upon the reliability of the work, of the measurements and the calculations of the authors. As very little information is contained in this Addendum concerning the methods of the work and the details of the measurements, it is necessary, in order to form an estimate of this reliability, to study carefully the previous paper published in the July, 1940, BULLETIN(3). Referring to the original paper, the present paper has this to say (bottom of page 379): "Here it may be remarked that we have made more money for Lake Shore digging into and forming the report than in obtaining the figures and data, and so far have never gone back to work on it without a resulting Lake Shore profit". Let me state that I, so far, have never gone back to work on it without finding more discrepancies and inconsistencies and illogical reasoning. In my first contribution to the discussion of the first paper, which discussion was published on page 355 and following, in the July, 1941, BULLETIN, I pointed out discrepancies and inconsistencies and illogical reasoning.

Jan 1, 1942

By Theophile Yameogo

Much has been said about the methodology of geomechanical design in underground excavations. However, the geological, hydrogeological and geotechnical complexities encountered at the production horizons in the Athabasca Basin commanded for a novel approach in the geomechanical assessment and design of underground openings. Rock mechanics engineers at Cameco McArthur River have been able to establish a practical methodology that goes beyond known conceptual approaches. In this paper, the author describes the original challenges and unique approach in the geomechanical assessment for drifts and chambers development. The example of the successful development of the 510-8225N Chamber will also be presented.

Aug 1, 2010

By S. E. Wolfe

AKNOWLEDGE of the density of a pulp or suspension is frequently required by the millman, to whom fluctuations in density, which occur in all mill circuits, are of importance and interest. There ,are many w.ays currently in use to determine density and probably the most common method is to take samples of the pulp. The proper sampling of the material is no easy matter, particularly when the pulp contains a sand fraction which settles rapidly. For example, when filling a liter container from the overflow of a classifier, it is al-most impossible to fill the can completely and yet prevent overflow. If there is an overflow, the pulp remaining in the can invariably has an excess of sand and the indicated density will be too high. To surmount such difficulties, and to obtain a continuous indication of the density of a pulp at any desired depth, the simple indicator shown diagrammatically in Figure l was designed by the writer in 1951. Its component parts, numbered as in Figure 1, are as follows.

Jan 1, 1958

By S. Esmaeili

The yield strength model developed by Esmaeili, Lloyd and Poole [1] has been adapted to model isothermal aging in Cu-containing AA6xxx alloys, with (a) a moderate and (b) a very low Cu content in the solution-treated, as-quenched, condition, Isothermal calorimetry has been used to analyze the kinetics of precipitation in these alloys, While the kinetic parameters for the low Cu alloy has been derived from the present experiments, the previously determined kinetic parameters for the high Cu alloy AA6111 has been used to model the precipitation kinetics in the moderate Cu alloy. The age hardening responses of both alloys have been well predicted by the model.

Jan 1, 2005

By A. Henk, C. M. Aruffo, K. Fischer

"Geomechanical reservoir modeling offers a valuable tool to predict tectonic stresses, in particular the local perturbations in orientation and/or magnitude which occur at lithological boundaries and faults. The paper presents a workflow for building and calibrating such geomechanical models. The numerical simulations are based on the Finite Element method and can range from field-scale models to smaller, highly detailed submodels of specific fault blocks. The approach considers the reservoir-specific characteristics with respect to subsurface geometry (lithostratigraphic boundaries, faults), mechanical properties and ambient stress field. During the subsequent calibration stage calculated stresses are compared to stress data actually observed in borehole data. Poorly constrained input parameters are iteratively modified within reasonable limits until a satisfactory fit between calculated and measured stresses is achieved. This validated model can then be used for stress predictions between wells and in undrilled parts of the reservoir, respectively. The workflow is applied to two case studies - a large gas field in Northern Germany and a CO2 sequestration project in Australia – to test and illustrate its practical value. INTRODUCTIONDetailed knowledge of the tectonic stress field is crucial for the optimal exploration and use not only of conventional and unconventional hydrocarbon reservoirs, but also for deep geothermal reservoirs, carbon capture and storage (CCS) projects as well as underground mining and nuclear waste repositories. Any reliable stress prediction is hindered by the observation that the magnitude and orientation of the stress field can vary significantly – not only in time, but also in space. Such spatial stress variations comprise all scales, i.e., from the scale of lithospheric plates down to the grain-scale. On the reservoir- and fault blockscale, the local stress field can be influenced by faults and different mechanical properties of lithologies (Sassi & Faure, 1997). The resulting variations in stress magnitude and/or stress orientation are commonly referred to as stress perturbations and give rise to a unique, reservoir-specific stress pattern (Yale, 2003). Thereby, local stress fields can deviate by up to 90° in orientation and several tenth of Megapascal (MPa) in magnitude from regional trends."

Jan 1, 2015

By J. E. Carrasco, J. D. Stinnette, R. A. Alvarez

"Chuquicamata Underground Mine is one of the main projects for the Chilean government copper company (CODELCO). Underground mine project has been under construction since 2013 and presents a solution for the lower production levels of the open pit and prolongs the life of the mine for the next 40 years. Currently, around 2000 workers operate in the mine daily. Dozens of trucks and heavy machines drives through all main routes and access in the mine. As a mine under construction not all the infrastructure necessary to operate safely in the mine has been completed. Risk of a truck or fixed facility fire is always a challenge to keep under control. One important part of fire simulation relays on what we can do prevent a fire and what can be done with the existing infrastructure to control a declared fire and start evacuation plans. This study has been made as a feasible emergency plan to implement, in this case, of a mine under construction, were limited resources are available. Several fire scenarios have been made to support all the emergency plan strategy and a detailed step by step procedure indicates what the elements of a fire emergency plan and risk analysis are.INTRODUCTIONThe main objective of this study is to describe the importance of fire risk analyses (FRAs) and different methods to be used before commencing fire simulation and methodology steps utilized for a fire emergency plan strategy (EPS) at the Chuquicamata underground mine. It also describes how to classify zones which are going to be affected by fumes and gases propagation derived from the exact location of a fire event. Fire simulation study is helpful to determine the impact on a ventilation system with the main purpose of providing relevant information to complement emergency plans and stablished control techniques in ventilation design and its operation. Most fire simulation studies only concentrates in simulation techniques on itself. But what is the next following step in developing an emergency plan? How can we evaluate, classify and treat risky areas? This study is focused mainly in the phases before and after a fire simulation process. Phases corresponds to a good FRA and how output data can be used for an EPS."

Jan 1, 2019

By T. A. Lazier, C. S. Longley

"Paymaster Consolidated Mines, Limited, owns several groups of claims in various parts of the Porcupine district. The area in which mining has been carried on includes parts of lots 5, 6, and 7, con. 1, Tisdale township, and twelve adjoining claims in Deloro township to the south. Highway No. 67A between South Porcupine and Timmins crosses the property.The discovery of the Dome mine in 1909 caused a rush of prospectors to the district and in a few weeks practically all territory adjacent to the Dome was staked. At that time work was started on the West Dome, West Dome Lake, Apex, and Standard properties. These were consolidated in 1930 to form the present Company. Gold was produced from the West Dome Lake from 1915 to 1930, and from the Standard-Paymaster from 1922 to 1928. The total production of the previous and present companies from 1915 to November 30, 1946, has been 487,170 oz. gold and 149,342 oz. silver from 2,337,554 tons of ore."

Jan 1, 1954

The mining industry has generally been slow to apply ion exchange processes to hydrometallurgical applications even if ion exchange offers an ideal solution for a particular problem. Two notable exceptions are in gold and uranium recovery. The largest application of ion exchange in the metals processing industry has been the use of resin-in-pulp (RIP) for gold recovery as an alternative to activated carbon. Iron is a ubiquitous impurity in hydrometallurgical solutions. In many cases, bulk removal of iron from the process solutions is accomplished by precipitation. However, precipitation for iron control is often accompanied by losses of base metals by co-precipitation. Increasingly, the option of ion exchange for removal of smaller amounts of iron from process solutions has been favoured. A number of applications have been developed and proven at the commercial scale for the removal/control of iron from a range of metal processing solutions. This paper provides an overview of the application of ion exchange for iron removal from a range of metal processing operations, including Cu, Ni and Co solutions. A number of case studies are provided which review operational and resin regeneration strategies and the impact upon the commercial operation of metal processing with improved iron control.

Jan 1, 2006

By D. J. Lucifora

Monitoring-While-Drilling (MWD) is a proven technique that records instantaneous on-drill parameters which can be used to supply contextual information for in-situ, down hole conditions, such as: changes in geology, the presence of pre-existing fractures and dynamic alterations, down hole conditions including bit bailing, bit blockages and bit wear, and improper drill operation. This technique has been widely used in the oil and gas industry and, eventually, it was transferred to the mining industry. A challenge when analyzing and interpreting MWD data is in utilizing proper filtering which enables one to properly eliminate any ?noise? from the signals of interest. Overall the importance of MWD data is that, through the collection of operational field-based data, a dataset can be acquired which allows experimentation and analysis to be carried out. Such a dataset is often impossible to replicate in a laboratory setting. If successful, and through iterative refinement, any promising method can eventually be implemented on-machine and using real-time monitoring techniques. This paper will provide a state of the art review of presently used MWD techniques and applications in industry. The paper?s primary focus will be on shallow, mining-style, blast hole drilling but will also take into account techniques and applications utilized in oil and gas drilling which have not been adopted in the mining industry. In the cases where MWD techniques and applications exist solely in oil and gas drilling the paper will examine and comment on the potential utility of technology transfer to mining applications.

Aug 1, 2013

By V. L. Mitsopoulos

This paper provides a summary of tailings disposal techniques and the improvements that have been made through the introduction of thickened tailings disposal. The general properties and characteristics of thickened tailings are described, as is a design process for selecting appropriate technologies for thickening, pumping, transporting and storing tailings. The factors affecting the selection of an appropriate disposal site and operational considerations for the effective utilisation of tailings storage areas are also documented.

Jan 1, 2006

By Mohammad. M. Khajeh

Rock mechanical properties are important parameters in geomechanical simulation. Considering stochastic heterogeneous models rather than conventional homogeneous layer cake models leads to more realistic simulation results and uncertainty assessment. These heterogeneous models are usually fine scale models generated by geostatistical techniques. Although considering high resolution property models is desirable, geomechanical simulation with a fine scale model is not computationally feasible for full?field, coupled geomechanical-flow simulation. Upscaling of property models is necessary to move from fine scale/high resolution property models to coarser scale/low resolution models appropriate for simulation. Local numerical upscaling was proposed by Khajeh et al. (2012) to describe the macroscopic elastic behavior of complex heterogeneous media and is expanded upon in this work. This numerical technique is not restricted to specific geologies as typical analytical techniques are. Moreover, transversely isotropic deformation is considered rather than the usual assumption of isotropic deformation. To compare the accuracy of the upscaling methodology, in this study shear strain is considered as the geomechanical response of a synthetic facies model and the response of the coarse scale model is compared to other conventional analytical averaging techniques. It is found that the numerical upscaling technique better approximates the geomechanical response of the fine scale model.

Jun 1, 2012

By Michael R. McPhie

Topics of Discussion 1. The Global Mining Initiative (GMI) and MMSD North America (Brief) 2. Task 2 of MMSD North America ? A Test for Sustainability 3. The Seven Questions and their Application 4. Key Recommendations and Next Steps GMI = Global Mining Initiative Significant international collaborative effort supported by more than 30 of the world?s largest mining/minerals firms which sought to involve all communities of interest. Three major streams of activities: 1. Mining, Minerals and Sustainable Development Project (MMSD) ? 4 regional Process (North America, Southern Africa, South America, Australia) 2. Creation of ICMM (formerly ICME) 3. Major conference in Toronto in May, 2002

May 1, 2002